Husqvarna 536LiP4 Instruction manual

Workshop Manual
English
536LiP4/530iP4,
536LiPT5/530iPT5,
536LiPX/530iPX

2 – English
Workshop Manual
Husqvarna 536LiP4530iP4, 536LiPT5/530iPT5,
536LiPX/530iPX
Table of contents
Table of contents
Husqvarna AB has a policy of continuous product development and therefore reserves the right to modify
the design and appearance of products without prior notice.
1 Introduction and safety regulations .......................... 3
1.1 General......................................................................... 3
1.2 Safety............................................................................ 3
1.3 Target group .............................................................. 3
1.4 Modications............................................................. 3
1.5 Tools.............................................................................. 3
1.6 Structure ..................................................................... 3
1.7 Numbering ................................................................ 3
1.8 General instructions ............................................... 4
1.9 Special instructions ................................................ 4
1.10 Limitations ................................................................. 4
1.11 Symbols on the pole saw ...................................... 4
1.12 Symbols in the Workshop Manual ..................... 4
2 Technical data .................................................................... 5
3 Service tool ........................................................................ 6
3.1 Diagnostic Tool Kit................................................... 6
3.2 Common Service Tool............................................. 6
4 Service data......................................................................... 7
5 Diagnosis and troubleshooting.................................12
5.1 Remove the battery ..............................................12
5.2 Connect the diagnostic tool .............................12
5.3 No signal to diagnostic tool...............................12
5.4 Troubleshooting the main switch....................13
5.5 Troubleshooting the BLDC control unit ........13
5.6 Overhaul ...................................................................13
6 Basic dismantle/assembly ...........................................15
6.1 Battery........................................................................15
6.2 Trigger guard...........................................................15
6.3 Battery housing skidplate...................................15
6.4 Control handle .......................................................16
6.5 Battery housing ......................................................16
6.6 Chain and bar ..........................................................16
7 Safety equipment ...........................................................17
7.1 Dismantling the throttle trigger lock and throt-
tle trigger ..................................................................17
7.2 Assembling the throttle trigger lock and throt-
tle trigger ..................................................................17
8 Repair instructions .........................................................18
8.1 General repair instructions.................................18
8.2 Dismantling the motor ........................................18
8.3 Assembling the motor .........................................20
8.4 Dismantling the oil tank......................................22
8.5 Assembling the oil tank.......................................22
8.6 Dismantling the oil pump and/or chain ten-
sioner, branch hook...............................................23
8.7 Assemble the oil pump and/or chain tension-
er, branch hook.......................................................23
8.8 Dismantling shaft and motor cabling
(536LiP4/530iP4, 536LiPX/530iPX)...................24
8.9 Assembling the shaft and motor cabling
(536LiP4/530iP4, 536LiPX/530iPX)...................25
8.10 Dismantling shaft and motor cabling
(536LiPT5/530iPT5)................................................26
8.11 Assembling shaft and motor cabling
(536LiPT5/530iPT5)................................................28
8.12 Changing the EMC lter ......................................30
8.13 Dismantling the main switch.............................31
8.14 Cleaning and inspection of the main switch32
8.15 Assembling the main switch..............................33
8.16 Dismantling the control cabling ......................34
8.17 Cleaning and inspection of the control ca-
bling............................................................................36
8.18 Assembling the control cabling .......................37
8.19 Dismantling the control unit .............................39
8.20 Assembling the control unit ..............................40
8.21 Changing the handle ...........................................41
9 Troubleshooting .............................................................42
10 Troubleshooting - battery and charger................44
11 Troubleshooting - Appendix....................................45

3 – English
1 Introduction and safety regulations
Introduction and safety regulations
1.1 General
This Workshop Manual provides a comprehensive
description of how to troubleshoot, repair and test
the pole saw. A description of dierent safety steps
that must be taken during repair work is also given.
1.2 Safety
Note! The section dealing with safety must be
read and understood by all those carrying out
repair work or service on the pole saw.
Warning symbols can be found in this Workshop
Manual and on the pole saw. See ”1.11 Symbols
on the pole saw” and ”1.12 Symbols in the Work-
shop Manual”. A new warning symbol decal must
be applied as soon as possible if a warning symbol
on the pole saw has been damaged or is missing
so that the greatest level of safety can be main-
tained when using the pole saw.
1.3 Target group
This Workshop Manual is written for personnel with
general knowledge about the repair and service of
trimmers.
The Workshop Manual must be read and under-
stood by personnel who will carry out repair work
and service on the pole saw. The Manual is also
suitable for use when training new employees.
1.4 Modications
Any modications to the pole saw will be gradually
introduced into ongoing production. As these mod-
ications aect service and/or spare parts, specic
service information will be sent out on each occa-
sion. This means that in time this Workshop Manu-
al will become out of date. In order to prevent this,
the Manual should be read together with all service
information concerning the pole saw in question.
1.5 Tools
Special tools are required for some stages. All
service tools are listed in the Workshop Manual.
Usage is made evident in each section.
Always use original Husqvarna:
• Spare parts
• Service tools
• Accessories
1.6 Structure
This Workshop Manual can be used in two dierent
ways:
• For the repair of a particular system on the pole
saw.
• For the dismantling and assembling of the entire
pole saw.
Repair of a particular system
When a particular system on the pole saw is to be
repaired, proceed as follows:
1. Look up the page for the system in question.
2. Carry out the following steps:
• Dismantling
• Cleaning and inspection
• Assembling
Dismantling and assembling the entire pole
saw.
When taking apart the whole pole saw and putting
it back together again, proceed as follows:
1. Open the chapter "6 Basic dismantle/assembly"
and carry out Dismantling in the order set out in
the sections.
2. Open the chapter "8 Repair instructions" and
carry out Dismantling in the order set out in the
sections.
3. Carry out Cleaning and inspection in the order
set out in the sections.
4. Carry out Diagnostic troubleshooting if a fault
in the electrical system is suspected.
5. Order or collect all requisite spare parts from the
stores.
6. Carry out Assembly in the order set out in the
sections.
1.7 Numbering
Position references to components in the gures
are designated A, B, etc.
The gures are numbered 1, 2 etc.
The position references and gure numbers restart
in each new section.

4 – English
1.8 General instructions
The workshop where the pole saw is to be repaired
must be equipped with safety devices in accor-
dance with local regulations.
No-one may repair the pole saw unless they have
read and understood the content of this Workshop
Manual rst.
This Workshop Manual contains the following
warning boxes in relevant places.
WARNING!
The warning box warns of the risk
of personal injury if the instruc-
tions are not followed.
NOTE!
This box warns of material damage if
the instructions are not followed.
1.9 Special instructions
Remove the battery from the pole saw before dis-
mantling and troubleshooting.
The battery must not be connected while the pole
saw is dismantled.
Never unscrew the battery. Replace a damaged
battery.
When using compressed air, do not direct the air
jet toward your body. Air can penetrate into the
blood circulation, which means mortal danger.
Use ear protection during testing.
1.10 Limitations
This Workshop Manual is intended mainly for the
repair of pole saw 536LiP4/iP4, LiPT5/iPT5, LiPX/
iPX.
1.11 Symbols on the pole saw
The pole saw keypad has the following symbols.
Starting/Stopping
savE / Battery saver mode
Warning lamp/Fault indicator
1.12 Symbols in the Workshop Manual
This symbol warns of personal injury
when the instructions are not followed.
Introduction and safety regulations

5 – English
Technical Data
Weight without battery
lbs/kg
536LiP4/530iP4 6.8 / 3.4
536LiPT5/530iPT5 11.0 / 5.0
536LiPX/530iPX 6.8 / 3.1
Chain speed, normal
operating rpm m/sec
536LiP4/530iP4 1/4" 18
536LiPT5/530iPT5 1/4" 18
536LiPX/530iPX 3/8 18
Chain speed, savE
rpm m/sec
536LiP4 1/4" 14.6
536LiPT5/530iPT5 1/4" 14.6
536LiPX/530iPX 3/8 14.6
Weight with battery (4.2 Ah)
Ibs/kg
10.1 / 4.7
13.7 / 6.3
9.7 / 4.4

6 – English
Technical Data
2 Technical data
3 Service tool
CST
INSTRUCTION
3.1 Diagnostic Tool Kit
3.2 Common Service Tool
The Common Service Tool (CST) is a service tool for Husqvarna products comprising Diagnostic Tool Kit
(583 89 71-01) and software for the installation of a PC.
If you have the previous "Engine Diagnostic Tool - AutoTune™" (576 69 23-01), it can be supplemented
with the "Adapter Cable for Battery Products" (579 62 13-01) to upgrade to the Diagnostic Tool Kit.
CST transmits various data from the product and battery to the computer, such as product ID. There is
also a troubleshooting guide in the form of a diagnostic tool and a list of saved error codes.
The software in battery powered products can also be updated with CST.
Pos Description Used with Order No.
1Diagnostic Tool Kit Diagnosis and troubleshooting 583 89 71-01
2 Adapter Cable for Battery Products Supplement/upgrade for Engine
Diagnostic Tool -AutoTune™
579 62 13-01
576 69 23-01

7 – English
Service data
Key
The numbers by bolted components represent the tightening torque in Nm.
* Tightening torque during inspection: 52 ft/lb (2.5 Nm)
Symbol used where
grease is to be used.
3 ~ 4 Nm 10 mm
6 ~ 8 Nm 4 mm
4 Service data

8 – English
Service data
Service data
LiPX
LiP4
LiPT5

9 – English
Service data
Service data
LiPX: S/N -20180200001, LiP4: S/N -20174600001, LiPT5: S/N -20174600122
LiPX, LiP4
LiPT5

10 – English
Service data
Service data
LiPX/iPX: S/N 20180200001-, LiP4/iP4: S/N 20174600001-,
LiPT5/iPT5: S/N 20174600122-
LiPX/iPX, LiP4/iP4
LiPT5/iPT5

11 – English
Service data
Service data

12 – English
Diagnosis and troubleshooting
5 Diagnosis and troubleshooting
Fig 2
Fig 1
5.1 Remove the battery
Press in the catches and remove the battery.
See gure 1.
WARNING!
The battery must always be removed
for service/repair work and may only
be put back once the pole saw has
been fully assembled again!
WARNING!
Do not short circuit the battery!
Never unscrew the battery!
Never t a damaged battery!
Replace a damaged battery!
5.2 Connect the diagnostic tool
1
Connect the adapter cable for the diagnostic tool to
the battery and the battery contact on the pole saw.
Connect cable (A) to the diagnostic tool for trouble-
shooting the pole saw.
Connect cable (B) to the diagnostic tool for trouble-
shooting the battery.
NB! Refer to the manual for the Diagnostic Tool
Battery for detailed instructions and follow the
instructions in the diagnostic tool.
See gure 2
2
Diagnose/troubleshoot according to the diagnostic
tool instructions and make any necessary repairs
as instructed in the relevant chapter in this manual.
5.3 No signal to diagnostic tool
1
Check that the contact on the battery and the bat-
tery contact on the pole saw are intact and clean.
Replace the battery or control unit on the pole saw
respectively if there is any damage.
2
Check that the cable to the diagnostic tool is intact
and clean. Replace the cable if it is damaged.
3
Restart the computer/Reinstall the software.
2
1
1
A B

13 – English
Diagnosis and troubleshooting
Fig 3
Fig 4
1 2 3 4 5 6
M1
B-
B+
B-
M
5.4 Troubleshooting the main switch
For products with S/N: -20180200001 (LiPX),
-20174600001 (LiP4), -20174600122 (LiPT5). See
gure 3.
The switch used in professional battery products
from Husqvarna has two functions, to supply
current to the control unit and the electric motor,
and act as a position sensor for the variable speed
control. All these functions can easily be tested and
veried using a resistance meter.
Note: The switch should not be depressed more
than 6 mm and not to its end position when
testing.
• Measure between B+ and B1 when the switch is
not depressed. The result should be open circuit.
• Measure between B+ and B1 when the switch is
depressed. The result should be closed circuit.
• Measure between pin 2 and pin 5 when the
switch is not depressed. The result should be
closed circuit.
• Measure between pin 2 and pin 5 when the switch
is depressed. The result should be 50kΩ ± 25 %.
• Measure between B1 and Pin 1. The result should
always be closed circuit.
If all readings are within specied limits, the switch
is OK.
For products with S/N: 20180200001- (LiPX/iPX),
20174600001- (LiP4/iP4), 20174600122- (LiPT5/
iPT5). See gure 4.
Use the Common Service Tool to check the func-
tionality of the main switch.

14 – English
5.6 Overhaul
Inspect the component parts of the pole saw. Re-
place damaged parts as described in the relevant
chapter.
A
C
B
Fig 5
5.5 Troubleshooting the BLDC control
unit
Check that the blade terminals and associated
wires are not bent or damaged.
(A) 4.8x0.8mm M phase (Gray wire)
(B) 4.8x0.8mm M phase (Black wire)
(C) 4.8x0.8mm M phase (Red wire)
See gure 5.
Diagnosis and troubleshooting

15 – English
Basic dismantle/assembly
6 Basic dismantle/assembly
The steps described below are the basic steps that must be carried out before any other service or repair
work or nal assembly is possible.
6.1 Battery
Press in the catches and remove the battery. See
gure 1.
Put the battery back once assembly has been
completed.
WARNING!
The battery must always be removed
for service/repair work and may only
be put back once the pole saw has
been fully assembled again!
NOTE!
Note how wires, components, etc., are posi-
tioned before dismantling.
Make sure to position them correctly to avoid
pinching when the pole saw is reassembled.
6.2 Trigger guard
Remove the screws and push the guard forward.
See gure 2.
6.3 Battery housing skidplate
Undo the screws and remove the skidplate from
the battery housing.
Assemble in the reverse order.
See gure 3.
2
1
1
Fig 1
Fig 2
Fig 3

16 – English
Basic dismantle/assembly
6.4 Control handle
Place something under the other handle half so
that it does not come loose from the shaft.
See gure 4.
Loosen the screws (6x) and lift o the handle.
See gure 5.
Assemble in the reverse order.
Tightening torque 2 ~ 3 Nm.
6.5 Battery housing
Loosen the screws (4x) and lift o half the battery
housing.
Assemble in the reverse order.
Tightening torque 2 - 3 Nm.
See gure 6.
6.6Chain and bar
Unscrew the bar nut and remove the motor cover.
Dismantle the circlip, washer and spur wheel.
Lift o the chain and bar.
Change circlip and washer if there are any visible
defects.
Assemble in the reverse order.
Seef igure 7.
WARNING!
Always use gloves when working
with cutting equipment.
Fig 4
Fig 5
Fig 6
Fig 7

17 – English
Safety equipment
7 Safety equipment
7.1Dismantling the throttle trigger lock
and throttle trigger
1
Dismantle the control handle as described in
"6Basic dismantle/assembly".
2
Lift o the throttle trigger lock and the throttle trig-
ger from their attachments in the handle.
See gure 1.
Cleaning and inspection
• Clean and check all parts thoroughly. Parts must
be replaced if cracked or showing signs of other
defects. Always use original spare parts.
• Check that the spring blade is intact and retains
all its tension.
See gure 2.
7.2Assembling the throttle trigger lock
and throttle trigger
1
Assemble the throttle and throttle lockout on their
respective attachments on the handle. Make sure
that the spring blade comes under the keypad.
See gure 3.
2
Assemble the control handle as described in "6Ba-
sic dismantle/assembly".
Fig 1
Fig 2
Fig 3

18 – English
8 Repair instructions
8.1General repair instructions
WARNING!
The battery must always be removed
for service/repair work and may only
be put back once the pole saw has
been fully assembled again!
8.2Dismantling the motor
1
Dismantle the screw holding the motor cover.
Dismantle the motor cover from its attachment.
2
Dismantle the chain, locking pin, washer and spur
wheel as well as the bar.
See gure 1.
3
Dismantle the cable guard, 2 screws.
See gure 2.
4
Unplug the connector from the motor.
Remove the cable holder.
See gure 3.
5
Unplug the connector.
See gure 4.
NOTE!
Note how wires, components, etc., are posi-
tioned before dismantling. Make sure to po-
sition them correctly to avoid pinching when
the pole saw is reassembled.
Repair instructions
Fig 1
Fig 2
Fig 3
Fig 4

19 – English
6
Dismantle the screws holding the saw head on the
shaft, 2 screws.
Carefully split the shaft and saw head.
See gure 5.
7
Extract the cables one by one from the saw head.
See gure 6.
8
Dismantle the screws, 4 pcs, holding the motor.
9
Press out the motor.
10
Press out the pump gear that drives the oil pump.
See gure 7.
Repair instructions
Fig 5
Fig 6
Fig 7

20 – English
Repair instructions
11
Change the gasket between the motor and motor
housing.
See gure 8.
Cleaning and inspection
Clean and check the motor. The motor must always
be replaced with a new one if cracked or showing
signs of other defects. Always use original spare
parts.
8.3Assembling the motor
1
Assemble the motor screws, 4 pcs, and assemble
the pump gear.
See gure 9.
2
Thread the cabling into the saw head.
Make sure the cables are positioned on the correct
side of the screw tower so the cables are not
pinched.
See gure 10.
Fig 8
Fig 9
Fig 10